Bone plate with transverse screw

ABSTRACT

An apparatus for a bone fusion assembly is provided for compressing adjacent bones across a bone fusion site to encourage fusion thereof. The bone fusion assembly includes a generally elongate member comprising a plate that has one or more fixation apertures to receive fasteners that are configured to be coupled with the adjacent bones. A threaded fastener comprising a bone screw, including a head portion and a shank, is configured to traverse the bone fusion site. A slanted aperture disposed in the plate is configured to receive the bone screw at a predetermined angle with respect to a plane of the plate. The slanted aperture comprises a smooth countersunk surface and one or more teeth that are configured to cooperate with the head portion of the bone screw to compress the adjacent bones together and encourage bone fusion therebetween.

PRIORITY

This application claims the benefit of and priority to U.S. patentapplication Ser. No. 16/821,598 filed on Mar. 17, 2020 and U.S. patentapplication Ser. No. 15/795,039 filed on Oct. 26, 2017, now issued U.S.Pat. No. 10,610,273 and U.S. Provisional Application, entitled “BonePlate With Transverse Screw,” filed on Nov. 7, 2016 and havingapplication Ser. No. 62/418,677.

FIELD

The field of the present disclosure generally relates to securing bonestogether. More particularly, the field of the invention relates to anapparatus for fusing and compressing bones of the human body.

BACKGROUND

A fusion bone plate implant may be utilized in conjunction with one ormore fasteners so as to generate compression and stability at a boneinterface. An implant coupled with fasteners generally serves tostabilize bones, or bone parts, relative to one another so as to promotebone fusion. In many applications, bone plates and fasteners are used tofuse bones, or bone parts, of the human body, such as bones in the foot,the ankle, the hand, the wrist, as well as various other portions of thebody. Furthermore, during the course of certain medical procedures, asurgeon may immobilize one or more bones or the bone fragments bystabilizing the bones together in a configuration which approximates thenatural anatomy. To this end, the surgeon may use fasteners to attachthe bones to a bone plate implant so as to hold the bones in alignmentwith one another while they fuse together.

SUMMARY

An apparatus for a bone fusion assembly is provided for compressingadjacent bones across a bone fusion site to encourage fusion thereof.The bone fusion assembly includes an elongate member comprising a platemade of a semi-rigid material possessing a tensile strength suitable forimmobilizing the adjacent bones. The plate includes one or more fixationapertures to receive fasteners that are configured to be coupled withthe adjacent bones. The plate may be implemented with one or moredirections of curvature, such that the plate matches an anatomical shapeof the adjacent bones. The bone fusion assembly further includes athreaded fastener comprising a bone screw, having a head portion and ashank, that is configured to traverse the bone fusion site. The shank iscomprised of distal threads and a proximal smooth portion. The distalthreads are configured to rotatably engage within a suitably sized holedrilled across the bone fusion site, and the proximal smooth portion isconfigured to pass through the bone with relatively little resistance. Aslanted aperture is disposed in the plate and configured to receive thebone screw at a predetermined angle with respect to a plane of theplate. The slanted aperture comprises a smooth countersunk surface andone or more teeth that are configured to cooperate with the head portionof the bone screw to compress the adjacent bones.

In an exemplary embodiment, a bone fusion assembly for compressingadjacent bones across a bone fusion site to encourage fusion thereofcomprises an elongate member comprising a plate that includes one ormore fixation apertures to receive fasteners that are configured to becoupled with the adjacent bones; a threaded fastener comprising a bonescrew that includes a head portion and a shank, the bone screw beingconfigured to traverse the bone fusion site; and a slanted aperturedisposed in the plate and configured to receive the bone screw at apredetermined angle with respect to a plane of the plate, the slantedaperture comprising a smooth countersunk surface and one or more teethconfigured to cooperate with the head portion to compress the adjacentbones.

In another exemplary embodiment, the one or more fixation apertures areconfigured to orient the fasteners substantially perpendicular to theplane of the plate. In another exemplary embodiment, the plate isimplemented with one or more directions of curvature, such that theplate matches an anatomical shape of the adjacent bones. In anotherexemplary embodiment, the one or more directions of curvature cause thefasteners to be oriented in the adjacent bones at differing angles withrespect to one another.

In another exemplary embodiment, the plate is comprised of a semi-rigidmaterial, such as a biocompatible metal or PEEK, possessing a tensilestrength suitable for immobilizing the adjacent bones. In anotherexemplary embodiment, the predetermined angle is an oblique angle thatis selected to direct the bone screw across the bone fusion site andcompress the adjacent bones together. In another exemplary embodiment,the predetermined angle ranges between substantially 35 degrees andsubstantially 45 degrees.

In another exemplary embodiment, the smooth countersunk surface and theone or more teeth are configured to slidably engage with an inferior endof the head portion during tightening of the bone screw into theadjacent bones. In another exemplary embodiment, the smooth countersunksurface and the one or more teeth are configured to cooperate with amaximal circumference of the head portion, such that a minimal portionof the head portion remains extending above an upper surface of theplate. In another exemplary embodiment, the maximal circumference isdisposed between a superior end and an inferior end of the head portion.

In another exemplary embodiment, the shank is comprised of distalthreads and a proximal smooth portion, the distal threads beingconfigured to rotatably engage within a suitably sized hole drilled inthe adjacent bones, and the proximal smooth portion being configured topass through the bone with relatively little resistance. In anotherexemplary embodiment, the head portion is comprised of a superior endand an inferior end, the superior end including a shaped openingconfigured to engagedly receive a tool suitable for driving the bonescrew into the suitably sized hole, and the inferior end beingconfigured to be received within the slanted aperture such that the headportion countersinks within the slanted aperture and presses the plateagainst a surface of the adjacent bones. In another exemplaryembodiment, a raised portion is disposed around the slanted aperture onan underside of the plate, the raised portion being a relatively thickerregion of the plate that is configured to provide structural support tothe plate and reduce an area of contact between the plate and theadjacent bones. In another exemplary embodiment, a raised portion isdisposed around each of the one or more fixation apertures. In anotherexemplary embodiment, each of the raised portions disposed around theone or more fixation apertures has a thickness that is substantially thesame as the thickness of the raised portion disposed around the slantedaperture.

In an exemplary embodiment, a bone screw for compressing adjacent bonesacross a bone fusion site comprises a head portion comprising a superiorend and an inferior end; a shaped opening disposed within the superiorend and configured to engagedly receive a tool for driving the bonescrew into a hole drilled across the fusion site; a shank extending fromthe inferior end, the shank comprising distal threads and a proximalsmooth portion; and a distal end configured to be advanced within thehole.

In another exemplary embodiment, the shaped opening is substantiallyconcentric with a longitudinal axis of the shank and comprises amulti-lobe shape suitable to receive the tool. In another exemplaryembodiment, the inferior end is configured to be received within aslanted aperture of a bone plate, such that the head portioncountersinks within the slanted aperture and presses the bone plateagainst the surface of the adjacent bones. In another exemplaryembodiment, a maximal circumference of the head portion is disposedbetween the superior end and the inferior ends so as to minimizeprotrusion of the head portion above an upper surface of the bone plate.

In another exemplary embodiment, the distal threads are configured torotatably engage within the hole, and wherein the proximal smoothportion is configured to pass through the bone with relatively littleresistance, the smooth portion being configured to allow the bone fusionsite to close as the adjacent bones are compressed together. In anotherexemplary embodiment, the distal end includes one or more shapes thatare configured to minimize resistance to forward movement of the bonescrew within the hole drilled in the adjacent bones. In anotherexemplary embodiment, the distal end comprises one or more flutes thatspiral along a portion of the distal threads and are configured to cleanan interior of the hole and remove bone debris therefrom.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings refer to embodiments of the present disclosure in which:

FIG. 1 illustrates an isometric view of an exemplary embodiment of abone fusion assembly that is configured to fixate adjacent bones so asto encourage bone fusion;

FIG. 2 illustrates a side plan view of the exemplary embodiment of thebone fusion assembly shown in FIG. 1 ;

FIG. 3 illustrates a top plan view of the exemplary embodiment of thebone fusion assembly shown in FIG. 1 ;

FIG. 4A illustrates an isometric view of an exemplary embodiment of abone screw that is configured to be coupled with a bone fusion plate forrepairing bone fractures, fixating osteotomies, joining fusions of theskeletal system, and the like;

FIG. 4B illustrates a side plan view of the exemplary embodiment of thebone screw of FIG. 4A;

FIG. 5A illustrates a side plan view of the exemplary embodiment of thebone screw of FIG. 4A and FIG. 4B disposed at an oblique angle within anexemplary bone fusion plate;

FIG. 5B illustrates a lower isometric view of the exemplary embodimentof the bone screw of FIG. 4A and FIG. 4B disposed within the exemplarybone fusion plate shown in FIG. 5A; and

FIG. 5C illustrates a top view of an exemplary embodiment of a slantedaperture disposed within the exemplary bone fusion plate shown in FIG.5A and FIG. 5B.

While the present disclosure is subject to various modifications andalternative forms, specific embodiments thereof have been shown by wayof example in the drawings and will herein be described in detail. Theinvention should be understood to not be limited to the particular formsdisclosed, but on the contrary, the intention is to cover allmodifications, equivalents, and alternatives falling within the spiritand scope of the present disclosure.

DETAILED DESCRIPTION

In the following description, numerous specific details are set forth inorder to provide a thorough understanding of the present disclosure. Itwill be apparent, however, to one of ordinary skill in the art that theinvention disclosed herein may be practiced without these specificdetails. In other instances, specific numeric references such as “firstscrew,” may be made. However, the specific numeric reference should notbe interpreted as a literal sequential order but rather interpreted thatthe “first screw” is different than a “second screw.” Thus, the specificdetails set forth are merely exemplary. The specific details may bevaried from and still be contemplated to be within the spirit and scopeof the present disclosure. The term “coupled” is defined as meaningconnected either directly to the component or indirectly to thecomponent through another component. Further, as used herein, the terms“about,” “approximately,” or “substantially” for any numerical values orranges indicate a suitable dimensional tolerance that allows the part orcollection of components to function for its intended purpose asdescribed herein.

In general, the present disclosure describes an apparatus for a bonefusion assembly configured to compress adjacent bones across a bonefusion site to encourage fusion thereof. The bone fusion assemblyincludes a generally elongate member comprising a plate that has one ormore fixation apertures to receive fasteners that are configured to becoupled with the adjacent bones. A threaded fastener comprising a bonescrew, including a head portion and a shank, is configured to traversethe bone fusion site. A slanted aperture disposed in the plate isconfigured to receive the bone screw at a predetermined angle withrespect to a plane of the plate. The predetermined angle may be anoblique angle that is selected to suitably orient the bone screw acrossthe bone fusion site. In some embodiments, the predetermined angleranges between substantially 35 degrees and 45 degrees with respect tothe plate of the plate. The slanted aperture comprises a smoothcountersunk surface and one or more teeth that are configured tocooperate with the head portion of the bone screw to compress theadjacent bones together and encourage bone fusion therebetween. Thesmooth countersunk surface and the one or more teeth cooperate with thehead portion such that a minimal extension of the head portion above anupper surface of the plate remains once the bone screw is tightened intothe adjacent bones.

FIGS. 1-3 illustrate an exemplary embodiment of a bone fusion assembly100 comprising a plate 104 that is configured to be coupled withadjacent bones, across a bone fusion site, so as to fixate the bones andencourage fusion of the bones. The bone fusion assembly 100 may beadvantageously used for repairing bone fractures, fixating osteotomies,joining fusions of the skeletal system, and the like. The plate 104comprises a generally elongate member having multiple fixation apertures112 that are configured to receive fasteners 108 such that the fastenersmay be coupled with the adjacent bones on opposite sides of a bonefusion site, such as a bone fracture to be fused. The fixation apertures112 are configured to orient the fasteners 108 substantiallyperpendicular to a plane of the plate 104. The plate 104 may beimplemented with one or more directions, or degrees, of curvature suchthat the plate matches an anatomical shape of a target bone to which thebone fusion assembly 100 is to be coupled. For example, the plate 104may be curved in a longitudinal direction and/or a lateral direction,without limitation. As shown in FIGS. 1-3 , the curvature of the plate104 may cause the fasteners 108 to be directed into the target bone atdiffering angles with respect to one another. The plate 104 may becomprised of a semi-rigid material, such as a biocompatible metal orPEEK, possessing a tensile strength suitable for immobilizing adjacentbone parts of the human body.

As best illustrated in FIGS. 1 and 3 , the plate 104 comprises a slantedaperture 116 that is configured to receive a threaded fastener 120 at apredetermined angle with respect to the plane of the plate 104. In someembodiments, the predetermined angle may be any oblique angle thatfacilitates compressing the adjacent bones together by way of thethreaded fastener 120 so as to encourage bone fusion. The oblique anglemay range between substantially 35 degrees and 45 degrees with respectto the plane of the plate 104, without limitation.

The threaded fastener 120 may be any component of hardware having a headconfigured to abut the surface of bone plate 104 and a shaft configuredto secure bones together in a fixed configuration. In some embodiments,the threaded fastener 120 may comprise a bone screw, or other similarfastener suitable for use in bone. In some embodiments, the threadedfastener 120 may comprise a lag screw which includes a head that isrounded or tapered and coupled to a shaft having an unthreaded portionadjacent to the head and a threaded portion that ends at a distal tip.FIGS. 4A-4B illustrate an exemplary embodiment of a bone screw 120 thatmay be advantageously used with the plate 104 for repairing bonefractures, fixating osteotomies, joining fusions of the skeletal system,and the like. It should be understood that the terms “bone screw,”“fastener,” “fixator,” and “screw” may be used interchangeably herein asthey essentially describe the same type of device.

The bone screw 120 generally is an elongate member comprised of a headportion 124 and a shank 128. The head portion 124 is comprised of asuperior end 132 and an inferior end 136. As best illustrated in FIG.4A, the superior end 120 may include a shaped opening 140 that issubstantially concentric with a longitudinal axis of the shank 128. Theshaped opening 140 may be configured to engagedly receive a toolsuitable for driving the bone screw 120 into a hole drilled in apatient's bone. Although in the illustrated embodiment, the shapedopening 140 is comprised of a hexalobe shape, any of various multi-lobeshapes, as well as other polygonal shapes, are also contemplated.

The inferior end 136 preferably is configured to be received within theslanted aperture 116, such that a majority of the head portion 124countersinks within the slanted aperture and presses the plate 104against the surface of the patient's bone. Further, a maximalcircumference 144 of the head portion 124 may be disposed between thesuperior and inferior ends 132, 136, such as substantially midwaybetween the superior and inferior ends, so as to minimize protrusion ofthe head portion 124 above an upper surface of the plate 104, as bestshown in FIG. 5A. As will be appreciated, limiting protrusion of thehead portion 104 above the plate 104 advantageously minimizes irritationto nearby soft tissue that may otherwise occur due to a relativelygreater presence of the head portion 124.

As best shown in FIG. 4B, the shank 128 is comprised of distal threads148 and a proximal smooth portion 152. The distal threads 148 areconfigured to rotatably engage within a suitably sized hole drilled inthe patient's bone. Thus, turning the bone screw 100 in an appropriatedirection by way of a tool coupled with the shaped opening 140, drivesthe distal threads 148 to engage with bone tissue surrounding the bonehole, advancing a distal end 156 of the bone screw 100 deeper into thebone hole and across a bone fracture to be fused. The proximal smoothportion 152 is configured to pass through the bone hole with relativelylittle resistance. Continued turning of the bone screw 100 thencountersinks the inferior end 136 into the slanted aperture 116, drawinga majority of the head portion 124 beneath the upper surface of theplate 104. Upon tightening the bone screw 120 into the bone, the distalthreads 148 push the bone portion near the distal threads toward thebone portion near the smooth portion 152 and the plate 124. The smoothportion 152 allows the fracture to close as the adjacent bone portionsare compressed together.

It is contemplated that the bone screw 120 may be particularly wellsuited for compressing bone fractures, fixating osteotomies, joiningfusions, as well as any other surgical procedure wherein compressing twoadjacent bone portions is desired, without limitation. As will beappreciated, the bone screw 120 may be implemented in any of variouslengths and diameters so as to advantageously repair a wide variety ofdifferently sized and shaped bones within the human body. Furthermore,it is envisioned that the bone screw 120 may be configured for use in aveterinary capacity, and thus the bone screw may be implemented withvarious shapes and sizes that are suitable for use in different types ofanimals.

In some embodiments, the distal end 156 may include one or more shapes,such as a rounded portion and a tapered diameter, that are configured tominimize resistance to forward movement of the bone screw 120 within theinterior of the bone hole. Further, one or more flutes may beincorporated into the distal end 156 and spiral along a portion of thedistal threads 148. It is contemplated that the flutes may be configuredto advantageously clean the interior of the bone hole and increase thediameter of the hole to accept the distal threads 148 of the advancingbone screw 120. As will be appreciated, the flutes may be configuredwith a spiral, or a rate of twist, that provides a desired rate of bonedebris removal from the interior of the bone hole during rotation of thebone screw 120. It is contemplated that the one or more flutes may beimplemented with any of various spirals without deviating beyond thespirit and scope of the present disclosure.

FIGS. 5A-5B illustrate an exemplary embodiment of the bone screw 120disposed at an oblique angle within the slanted aperture 116 of theplate 104. FIG. 5C is a top view of the slanted aperture 116 in absenceof the bone screw 120. The slanted aperture 116 is comprised of a smoothcountersunk surface 160 and teeth 164 that are configured to slidablyengage with the inferior end 136 of the bone screw 120. The teeth 164are configured to allow passage of the distal threads 148 therebetweenand capture the head portion 124 during tightening of the bone screw 120into the target bone. The smooth countersunk surface 160 generallyorients the bone screw 120 at an oblique angle relative to the plate104, as shown in FIG. 5A. Although the oblique angle may range betweensubstantially 35 degrees and 45 degrees, as stated hereinabove, it is tobe understood that the bone screw 120 may be oriented with respect tothe plate 104 at any angle that is suitable for compressing the adjacentbones to be fused, without limitation. Moreover, although in theembodiment illustrated in FIG. 5C, two of the teeth 164 are disposedwithin the slanted aperture 116, it should be understood that more orless than two of the teeth 164 may be incorporated into the slantedaperture without limitation.

The countersunk surface 160 and the teeth 164 cooperate with the maximalcircumference 144 of the bone screw 120 to allow the head portion 124 toseat relatively deeply into the slanted aperture 116 such that a minimalportion of the head portion 124 remains extending above an upper surface168 of the plate 104. Further, as shown in FIG. 5B, a raised portion 172may be disposed around the slanted aperture 116 on an underside 176 ofthe plate 104. Similar raised portions 172 may be disposed around eachof the fixation apertures 112, without limitation. Preferably, each ofthe raised portions 172 around the fixation apertures 112 has athickness that is substantially the same as the thickness of the raisedportion around the slanted aperture 116. The raised portions 172 arerelatively thicker regions of the plate 104 that may be configured toprovide structural support to the apertures 112, 116, as well as togenerally reduce an area of contact between the plate 104 and the targetbone.

While the invention has been described in terms of particular variationsand illustrative figures, those of ordinary skill in the art willrecognize that the invention is not limited to the variations or figuresdescribed. In addition, where methods and steps described above indicatecertain events occurring in certain order, those of ordinary skill inthe art will recognize that the ordering of certain steps may bemodified and that such modifications are in accordance with thevariations of the invention. Additionally, certain of the steps may beperformed concurrently in a parallel process when possible, as well asperformed sequentially as described above. To the extent there arevariations of the invention, which are within the spirit of thedisclosure or equivalent to the inventions found in the claims, it isthe intent that this patent will cover those variations as well.Therefore, the present disclosure is to be understood as not limited bythe specific embodiments described herein, but only by scope of theappended claims.

What is claimed is:
 1. A bone fusion assembly for compressing adjacentbones across a bone fusion site to encourage fusion thereof, comprising:an elongate member comprising a plate that includes one or more fixationapertures to receive fasteners that are configured to be coupled withthe adjacent bones; a threaded fastener comprising a bone screw thatincludes a head portion and a shank, the bone screw being configured totraverse the bone fusion site; and a slanted aperture disposed in theplate and configured to receive the bone screw at a predetermined anglewith respect to a plane of the plate, the slanted aperture comprising asmooth countersunk surface and one or more teeth configured to cooperatewith the head portion to compress the adjacent bones.
 2. The assembly ofclaim 1, wherein the one or more fixation apertures are configured toorient the fasteners substantially perpendicular to the plane of theplate.
 3. The assembly of claim 1, wherein the plate is implemented withone or more directions of curvature, such that the plate matches ananatomical shape of the adjacent bones.
 4. The assembly of claim 3,wherein the one or more directions of curvature cause the fasteners tobe oriented in the adjacent bones at differing angles with respect toone another.
 5. The assembly of claim 1, wherein the plate is comprisedof a semi-rigid material, such as a biocompatible metal or PEEK,possessing a tensile strength suitable for immobilizing the adjacentbones.
 6. The assembly of claim 1, wherein the predetermined angle is anoblique angle that is selected to direct the bone screw across the bonefusion site and compress the adjacent bones together.
 7. The assembly ofclaim 6, wherein the predetermined angle ranges between substantially 35degrees and substantially 45 degrees.
 8. The assembly of claim 1,wherein the smooth countersunk surface and the one or more teeth areconfigured to slidably engage with an inferior end of the head portionduring tightening of the bone screw into the adjacent bones.
 9. Theassembly of claim 1, wherein the smooth countersunk surface and the oneor more teeth are configured to cooperate with a maximal circumferenceof the head portion, such that a minimal portion of the head portionremains extending above an upper surface of the plate.
 10. The assemblyof claim 9, wherein the maximal circumference is disposed between asuperior end and an inferior end of the head portion.
 11. The assemblyof claim 1, wherein the shank is comprised of distal threads and aproximal smooth portion, the distal threads being configured torotatably engage within a suitably sized hole drilled in the adjacentbones, and the proximal smooth portion being configured to pass throughthe bone with relatively little resistance.
 12. The assembly of claim11, wherein the head portion is comprised of a superior end and aninferior end, the superior end including a shaped opening configured toengagedly receive a tool suitable for driving the bone screw into thesuitably sized hole, and the inferior end being configured to bereceived within the slanted aperture such that the head portioncountersinks within the slanted aperture and presses the plate against asurface of the adjacent bones.
 13. The assembly of claim 1, wherein araised portion is disposed around the slanted aperture on an undersideof the plate, the raised portion being a relatively thicker region ofthe plate that is configured to provide structural support to the plateand reduce an area of contact between the plate and the adjacent bones.14. The assembly of claim 13, wherein a raised portion is disposedaround each of the one or more fixation apertures.
 15. The assembly ofclaim 14, wherein each of the raised portions disposed around the one ormore fixation apertures has a thickness that is substantially the sameas the thickness of the raised portion disposed around the slantedaperture.
 16. A bone screw for compressing adjacent bones across a bonefusion site, comprising: a head portion comprising a superior end and aninferior end; a shaped opening disposed within the superior end andconfigured to engagedly receive a tool for driving the bone screw into ahole drilled across the fusion site; a shank extending from the inferiorend, the shank comprising distal threads and a proximal smooth portion;and a distal end configured to be advanced within the hole.
 17. The bonescrew of claim 16, wherein the shaped opening is substantiallyconcentric with a longitudinal axis of the shank and comprises amulti-lobe shape suitable to receive the tool.
 18. The bone screw ofclaim 16, wherein the inferior end is configured to be received within aslanted aperture of a bone plate, such that the head portioncountersinks within the slanted aperture and presses the bone plateagainst the surface of the adjacent bones.
 19. The bone screw of claim18, wherein a maximal circumference of the head portion is disposedbetween the superior end and the inferior ends so as to minimizeprotrusion of the head portion above an upper surface of the bone plate.20. The bone screw of claim 16, wherein the distal threads areconfigured to rotatably engage within the hole, and wherein the proximalsmooth portion is configured to pass through the bone with relativelylittle resistance, the smooth portion being configured to allow the bonefusion site to close as the adjacent bones are compressed together. 21.The bone screw of claim 16, wherein the distal end includes one or moreshapes that are configured to minimize resistance to forward movement ofthe bone screw within the hole drilled in the adjacent bones.
 22. Thebone screw of claim 16, wherein the distal end comprises one or moreflutes that spiral along a portion of the distal threads and areconfigured to clean an interior of the hole and remove bone debristherefrom.